• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 1996.03b
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• pp.16-22
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• 1996

Two kinds of blank shapes, optimum and square, are adopted to investigate formbility. Optimum blank shape is determined to construct an L-shape cup with uniform height and without flange part. For this purpose , rigid-plastic FEM analysis is applied with backward tracing technique. Maximum cup detph and strain distribution are measured experimetally for the products of the two kinds of blank shapes, which are optimum and square.It is confirmed that deeper cup without severe thickness reduction can be obtained fro the optimum shape.

• Transactions of the Korean Society of Mechanical Engineers
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• v.15 no.1
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• pp.145-153
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• 1991

A numerical simulation of the nonsteady state rolling process in the plane strain condition is presented in the basis of the rigid-plastic finite element method by considering large deformation. In order to apply the large deformation theory to the numerical method for sheet rolling problems, constitutive equation relating 2nd-Piola Kirchhoff stress and Lagrangian strain which reflect geometrical nonlinearity is used. To confirm the validity of the developed algorithm, the analysis of the neutral flow region, roll separating force, torque, pressure and stress/strain distributions on the workpiece is conducted from the bite of the material until the steady state is reached. The computed results of the roll force and torque in the present finite element analysis are lower than those corresponding to small strain theory. The pressure distribution at the work piece-roll interface is found to show the typical 'friction hill' type only. The peak value in near the neutral region, however, is good agrements with the existing results. the neutral region, however, is good agrements with the existing results. The frictional force at the roll interface provide detailed information about the neutral point where the shear forces change direction. In addition, the analysis also includes the effect and influence of material condition, strip thickness, work roll diameter, as well as roll speed and lubricant on each deformation process.

• Transactions of Materials Processing
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• v.3 no.1
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• pp.120-132
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• 1994

Strip drawing of strain-hardening, viscoplastic materials with damage is analyzed by a rigid plastic finite element method. A process model is formulated using two state variables, one for strain hardening from slip dominated plastic distortion and the other for damage from growth of microvoids. Application of the model to aluminum strip drawing is given via implementation in a consistent penalty finite element formulation. The predicted density changes as a result of void growth are compared to those from experiments reported in the literature. The effects of drawing conditions such as drawing speed and die angle on the mechanical property chages are studied.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.20 no.7
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• pp.2118-2133
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• 1996

A preform is designed by the backward tracing scheme of the rigid-plastic finite element method(FEM) for net-shape shell nosing components without machining after forming. The current process of the shell nosing requires cost-consuming machining to produce final products. Here, the backward tracing scheme of the rigid-plastic FEM, a novel method for preform design of metal forming processes, derives a sound preform for net-shape shell nosing product. The current process is simulated by the rigid-plastic finite element analysis to check the metal flow involved in the forming with a trial preform and its modified preform. The two preforms are found to be inadequate for net-shape shell nosing product. The first application of the back ward tracing scheme derives a preform producing a not-shape shell nosing product. The first application of the backward tracing scheme derives a preform producing a net-shape product numerically, but it is difficult to be formed economically as a preform. Thus an improved preform is designed by the badkward tracing scheme, which is suitable for net-shape manufacturing of the shell nosing components in view of economy of production and forming characteristics of the product. The preform in the current process and a modified preform are confirmed by a series of experiments and the results give the same deformation with the numerical ones. Finally the newly designed preform by the FEM was experimentally proved to be adequate in obtaining net-shape products.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.27 no.5
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• pp.815-822
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• 2003

The ring rolling process involves not only three-dimensional non-steady material flow and continuous change of radius and thickness of the ring workpiece but also heat transfer among workpiece, rolls and environment. In this study, deformation and heat transfer analyses were conducted by using the three-dimensional thermo-rigid-plastic finite element method. Three cases of plain ring rolling process were, respectively, simulated for the predictions of roll forces and the highest temperature zone during the aluminum process that ductile fracture often occurs. In addition, to prevent fishtail phenomena of the ring workpiece, axial rolls were used for this study.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.1101-1104
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• 2004

A brake spider in an irregular shape, which is used as a part in the braking system of a vehicle like a big truck and a trailer, is subjected to a large torque and hence requires both strength and endurance over the brake heat. Manufacture of this product in practice is generally composed of hot forging processes and machining. At the present study, two or more processes were considered for the hot forging. With an initial circular billet, blocker and finisher processes were analyzed using the rigid-plastic finite element method and also in addition to the preforming process. Proper forging processes to manufacture an irregular product without forging defects, which are preforming, blocker and finisher, were discussed and commented upon.

• Proceedings of the Korean Society of Precision Engineering Conference
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• 2004.10a
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• pp.1097-1100
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• 2004

A rear axle spider in an irregular shape, which is used as a part in the braking system of a vehicle like a big truck and a trailer, is subjected to a large torque and hence requires both strength and endurance over the brake heat. This part should be therefore manufactured in dimensional accuracy. The practical manufacturing process of this irregular product requires the heat treatment process after hot forging and then the cold coining process for the dimensional accuracy. At the present study, the warm coning without the heat treatment process was proposed to employ the residual heat due to the hot forging process. And also the trimming and piercing process was designed using the rigid-plastic finite element method. The mechanical properties were discussed and also commented upon.

• Proceedings of the Korean Society for Technology of Plasticity Conference
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• 2000.10a
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• pp.82-85
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• 2000

In cold forging, the final product is usually given by multi-stage process and the preform with stepped shape can be manufactured through the various forging method. The forward extrusion and upsetting processes for preform with stepped shape have been analyzed by using the rigid-plastic finite element analysis code, InteFORM and compared for load and stroke according to ae reduction of weを An engineer should select the proper processes considering the capacity and the stroke of the corresponding press in the forging of the preform with stepped shape.

• Transactions of the Korean Society of Mechanical Engineers
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• v.13 no.6
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• pp.1070-1081
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• 1989

본 논문의 목적은 일반적인 곡면을 갖는 냉간단조 공정을 컴퓨터 시뮬레이션 을 통해 해석하고자 강소성 유한요소법의 프로그램을 개발하고, 이를 축대칭 및 평면 변형 단조성형에 적용하고자 한다. 축대칭 문제로는 산업적으로 이용이 많은 치차 블랭크(gear blank) 형태의 예제를 선택하였고 평면변형으 경우 정밀 단조품의 하나인 터어빈 블레이드(turbine blade)를 평면변형 문제로 보아 해석하였다. 한편 심한 변형을 하는 후방압출과 같은 문제의 수렴성을 향상시키고 공정을 계속적으로 해석하 기 위하여 격자 재구성기법을 도입함으로서 냉간단조 문제의 일반적인 해석을 하도록 한다.

• Journal of the Korean Society for Precision Engineering
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• v.15 no.1
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• pp.152-159
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• 1998

Two angle-shaped extrusions have been studied in order to analyze the bending effect of the extruded product using the three-dimensional rigid-plastic finite element method. The velocity distribution at the outlet becomes the source for the construction of the bending configuration of the final product. in which an analytic scheme has been developed for the description of the bending. A systematic approach presented here appears to have sound agreement with the experimental result, and has been applied to a large extrusion of aluminum alloy.